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2007 ARCTIC
Prowler Service
CATManual
ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2007-prowler-service-manual/
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2007 Arctic
Cat Prowler/XT. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-
low the directive because it deals with the possibility of severe personal injury or even death. The symbol
! CAUTION identifies unsafe practices which may result in vehicle-related damage. Follow the directive because
it deals with the possibility of damaging part or parts of the vehicle. The symbol NOTE: identifies supplementary
information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and
specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
TABLE OF CONTENTS
Foreword
Click on the red text to go.
Section
1. General Information 1
2. Periodic Maintenance/Tune-Up 2
3. Engine/Transmission 3
4. Fuel/Lubrication/Cooling 4
5. Electrical System 5
6. Drive System 6
7. Suspension 7
8. Steering/Frame 8
9. Controls/Indicators 9
2007
10. Aids for Maintenance
11. Troubleshooting
10
11
Prowler
Prowler
Prowler XT
Service Manual
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TABLE OF
CONTENTS
General Specifications*
CARBURETOR CHASSIS
Type Keihin CVK36 Dry Weight (approx) 526 kg (1160 lb)
Main Jet 132 Length (overall) 292 cm (115 in.)
Slow Jet 40 Height (overall) 197 cm (77.5 in.)
Low Speed Fuel Screw Setting 1 1/4 Width (overall) 156 cm (61.3 in.)
(turns)
Suspension Travel (front) 25.4 cm (10 in.)
Jet Needle Fixed (rear) 25.4 cm (10 in.)
Needle Jet 6.0/4.0 Brake Type Hydraulic
Idle RPM 1250-1350 Wheelbase 190 cm (75 in.)
Starter Jet 85 Tracking (front) 128.3 cm (50.5 in.)
(rear) 123.2 cm (48.5 in.)
Float Arm Height 17 mm (0.7 in.)
Tire Size (front) 26 x 9-14
ELECTRICAL (rear) 26 x 11-14
Ignition Timing 10° BTDC @ 1500 RPM Tire Inflation Pressure 0.70 kg/cm² (10 psi)
Spark Plug Type Champion RG6YC Turning Radius 3.3 m (10.8 ft)
Spark Plug Gap 0.7-0.8 mm MISCELLANY
(0.028-0.032 in.)
Gas Tank Capacity (rated) 31 L (8.2 U.S. gal.)
Spark Plug Cap 3750-6250 ohms
Coolant Capacity 2.9 L (3.0 U.S. qt)
Ignition Coil (primary) Less than 1 ohm
Resistance (terminal to ground) Differential Capacity 275 ml (9.3 fl oz)**
(secondary) 5200-7800 ohms
(high tension - plug cap Rear Drive Capacity 250 ml (8.5 fl oz)**
removed - to ground)
Engine Oil Capacity 2.5 L (2.6 U.S. qt)
Ignition Coil Peak Voltage 142.4-213.6 DC volts
(primary/CDI) (blue/white to ground) Gasoline (recommended) 87 Octane Regular
Unleaded
Magneto Coil (trigger) 160-240 ohms
Resistance (green to blue) Engine Oil (recommended) SAE 5W-30
(source) Less than 1 ohm Differential/Rear Drive SAE Approved
(yellow to white) Lubricant 80W-90 Hypoid
(charging) Less than 1 ohm
(black to black) Belt Width 35.0 mm (1.38 in.)
Magneto Coil Peak (trigger) 4.2-6.3 volts Brake Fluid DOT 4
Voltage (green to blue)
(source) 0.40-0.62 volt Taillight/Brakelight 12V/8W/27W
(yellow to white) Headlight 12V/27W (2)
Stator Coil Output (no load) 60 AC volts @ 5000 RPM Starting System Electric
(black to black)
* Specifications subject to change without notice.
Magneto Output (approx) 325W @ 5000 RPM
** 1 inch below plug threads.
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NOTE: Do not be reluctant to heat up the brake
pads during the burnishing procedure.
Break-In Procedure
After the completion of the break-in period, the
engine oil and oil filter should be changed. Other
A new vehicle and an overhauled engine require a maintenance after break-in should include checking
“break-in” period. The first 10 hours (or 200 miles) of all prescribed adjustments and tightening of all
are most critical to the life of this vehicle. Proper fasteners.
operation during this break-in period will help
assure maximum life and performance from the
vehicle.
Gasoline - Oil -
During the first 10 hours (or 200 miles) of operation, Lubricant
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the compo-
nents to “load” (aiding the mating process) and then
1
RECOMMENDED GASOLINE
“unload” (allowing components to cool). Although
it is essential to place some stress on the engine The recommended gasoline to use is 87 minimum
components during break-in, care should be taken octane regular unleaded. In many areas, oxygenates
not to overload the engine too often. Do not pull a (either ethanol or MTBE) are added to the gasoline.
trailer or carry heavy loads during the 10-hour Oxygenated gasolines containing up to 10% ethanol,
break-in period. 5% methane, or 5% MTBE are acceptable gasolines.
When the engine starts, allow it to warm up prop- When using ethanol blended gasoline, it is not nec-
erly. Idle the engine several minutes until the engine essary to add a gasoline antifreeze since ethanol will
has reached normal operating temperature. Do not prevent the accumulation of moisture in the fuel sys-
idle the engine for excessively long periods of time. tem.
During the break-in period, a maximum of 1/2 throt-
tle is recommended; however, brief full-throttle ! CAUTION
accelerations and variations in driving speeds con- Do not use white gas. Only Arctic Cat approved gas-
tribute to good engine break-in. oline additives should be used.
During the break-in period (or whenever the brake
RECOMMENDED ENGINE/
pads are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must TRANSMISSION OIL
be properly burnished in order to achieve maximum
stopping power. ! CAUTION
Any oil used in place of the recommended oil could
! CAUTION cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These
BRAKE PADS MUST BE BURNISHED TO ACHIEVE
oils can adversely affect clutch operation. Also, not
FULL BRAKING EFFECTIVENESS. Braking distance
recommended are racing, vegetable, non-detergent,
will be extended until brake pads are properly bur-
and castor-based oils.
nished.
TO PROPERLY BURNISH THE BRAKES, USE FOL-
The recommended oil to use is Arctic Cat 4-Cycle
LOWING PROCEDURE:
Engine Oil or an equivalent oil which is rated SE,
• Choose an area sufficiently large to safely accel- SF, or SG under API service classification. These
erate vehicle to 30 mph and to brake to a stop. oils meet all of the lubrication requirements of the
• Accelerate to 30 mph; then apply the brake to Arctic Cat engine. The recommended engine oil vis-
decelerate to 0-5 mph. cosity is SAE 5W-30. Ambient temperature should
• Repeat procedure five times until brakes are bur- determine the correct weight of oil. See the follow-
nished. ing viscosity chart for details.
• This procedure burnishes the brake pads, stabi-
lizes the pad material, and extends the life of the
brake pads.
! WARNING
Do not attempt sudden stops or put the vehicle into
a situation where a sudden stop will be required
until the brake pads are properly burnished.
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Since gasoline expands as its temperature rises, the
gas tank must be filled to its rated capacity only.
Expansion room must be maintained in the tank par-
ticularly if the tank is filled with cold gasoline and
then moved to a warm area.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the
engine to cool before filling the gas tank.
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3. Either drain the gas tank or add Fuel Stabilizer 3. Check all control wires and cables for signs of
to the gas in the gas tank. Remove the air filter wear or fraying. Replace if necessary.
housing cover and air filter. Start the engine and
allow it to idle; then using Arctic Cat Engine 4. Change the engine/transmission oil and filter.
Storage Preserver, rapidly inject the preserver
into the air filter opening for a period of 10 to 20 5. Check the coolant level and add properly mixed
seconds; then stop the engine. Install the air fil- coolant as necessary.
ter and housing cover.
6. Charge the battery; then install. Connect the bat-
tery cables.
! CAUTION
If the interior of the air filter housing is dirty, clean
! CAUTION
the area before starting the engine.
The ignition switch must be in the OFF position prior
4. Drain the carburetor float chamber. to installing the battery or damage may occur to the
ignition system.
1
5. Plug the exhaust hole in the exhaust system with
a clean cloth. ! CAUTION
Connect the positive battery cable first; then the
6. Apply light oil to the plungers of the shock negative.
absorbers.
7. Check the entire brake systems (fluid level,
7. Tighten all nuts, bolts, cap screws, and screws. pads, etc.), all controls, headlights, taillight,
Make sure rivets holding components together brakelight, and headlight aim; adjust or replace
are tight. Replace all loose rivets. Care must be as necessary.
taken that all calibrated nuts, cap screws, and
bolts are tightened to specifications (see Section 8. Tighten all nuts, bolts, cap screws, and screws
10). making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications (see Section
8. Fill the cooling system to the bottom of the 10).
stand pipe in the radiator neck with properly
mixed coolant. 9. Check tire pressure. Inflate to recommended
pressure as necessary.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and 10. Make sure the steering moves freely and does
store in a clean, dry area. not bind.
10. Store the vehicle indoors in a level position. 11. Check the spark plug. Clean or replace as neces-
sary.
! CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
vehicle causing rusting.
Preparation After
Storage
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SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
TABLE OF
CONTENTS
Initial
Every Month Every 3 Every 6
Service After Every Year
Every or Months or Months or As
Item Break-In or Every
Day Every 100 Every 300 Every 500 Needed
(First Mo or 1500 Miles
Miles Miles Miles
100 Mi)
Battery I I C
Fuses I R
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester C R
Gas/Vent Hoses I I R (2 Yrs)
Throttle Cable Ends/Accelerator Pedal I I C-L A-R
Pivot
Carb Float Chamber D*
Engine RPM (Idle) I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R* R
Oil Strainer I I C
Front Differential/Rear Drive Lubricant I I R (4 Yrs)
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive I I R
axle boots front and rear, tie rods, dif-
ferential and rear drive bellows)
Nuts/Bolts/Cap Screws T T A
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever I A-L
Gauges/Indicators I I R
Frame/Welds I I l
Electrical Connections l C
Complete Brake System I I
(Hydraulic & Parking)
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)
Wheel Lug Nuts T T
* Service/Inspect more frequently when operating in adverse conditions.
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Arctic CatFOR
2007 ARCTIC
Prowler Service
CATManual
ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2007-prowler-service-manual/
! WARNING
Lubrication Points
Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame,
cigarettes, or any other flame away. Always wear
It is advisable to lubricate certain components peri- safety glasses. Protect skin and clothing when han-
odically to ensure free movement. Apply light oil to dling a battery. When servicing battery in enclosed
the components using the following list as reference. space, keep the area well-ventilated. Make sure bat-
tery venting is not obstructed.
A. Accelerator Pedal Pivot/Cable Ends
1. Remove the fasteners holding the left-rear
B. Brake Pedal Pivot splash panel in place; then remove the battery
access panel.
C. Parking Brake Cable Ends
D. Shift Linkage
E. Differential Lock Cable End (XT)
F. Idle RPM Screw (Carburetor)
2
Battery
PR054A
! WARNING
Avoid spillage and contact with skin, eyes, and
clothing.
! CAUTION
AF879D
The level of the battery fluid must be kept between Do not charge the battery while it is in the vehicle
the upper and lower level lines at all times. If the with the battery terminals connected.
level drops below the lower level line, add only dis-
tilled water until it reaches upper level line. 3. Remove the vent plugs; then (if necessary) fill
the battery with distilled water to the UPPER
level indicated on the battery.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or NOTE: Electrolyte should be at room tempera-
clothing. Care must be taken whenever handling a ture before filling. Do not use water or any other
battery. liquid to activate a battery.
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